King Kutter Operation Manual

ROTARY MOWEROPERATION AND PARTS

MANUAL

PO Box 1200305 Commerce DriveWinfield, Alabama 35594

Part No 999998 www.kingkutter.com

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TO THE PURCHASER

This manual contains valuable information about your newKing Kutter Mower. It has been carefully prepared to give youhelpful suggestions for operating, adjusting, servicing andordering repair parts.

Keep this manual in a convenient place for quick and easyreference. Study it carefully. You have purchased a depend-able and sturdy mower, but only by proper care and operationcan you expect to receive the service and long life designedand built into it.

Sometime in the future your mower may need new parts toreplace those that are worn or broken. If so, go to your dealerand provide him with the model and part number.

Customer Information

Name______________________________________________

Purchased From ______________________________________

Date Purchased ______________________________________

Model No. ___________________________________________

Serial No. ___________________________________________

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It is the purchaser and/or operator’s responsibility to….

Read and understand the information contained in thismanual.

Operate, lubricate, assemble and maintain the equip-ment in accordance with all instructions and safety pro-cedures in this manual.

Inspect the equipment and replace or repair any partsthat are damaged or worn which under continued opera-tion would cause damage, wear to other parts, or causea safety hazard.

Return the equipment or parts to the authorized KingKutter dealer, from where it was purchased, for serviceor replacement of defective parts that are covered bywarranty. (The King Kutter Factory may inspect equip-ment or parts before warranty claims are honored.)

Payment of all costs incurred by the dealer for travelingto or transporting the equipment for warranty inspec-tion and or claims.

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CONTENTS

ITEM PAGE

Safety ......................................................................... 6

Assembly Instructions ................................................ 8

Before Putting Into Service ...................................... 11

Safety Training ......................................................... 12

Operational Safety ................................................... 14

Transportation Safety ............................................... 16

Attaching To Tractor ................................................. 17

Sizing PTO ............................................................... 19

Operating Instructions.............................................. 20

Maintenance ............................................................. 22

Maintenance Safety ................................................. 23

Safety Decal's And Locations................................... 24

PTO Shaft Parts ....................................................... 29

Replacement Parts................................................... 32

PTO Shaft Cover Removal......................................37

Gearbox Parts .......................................................... 40

Warranty ................................................................... 46

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SIGNAL WORDS:

The signal words DANGER, WARNING and CAUTION are used with thesafety messages in this manual and with each safety signs. They aredefined as follows:

DANGER: Indicates an immediate hazardous situation that, if not avoided,could result in serious injury or death. This signal word is to be limited to themost extreme situations typically for machine components that, for func-tional purposes, cannot be guarded.

WARNING: Indicates a potentially hazardous situation that, if not avoided,could result in serious injury or death, and includes hazards that are ex-posed when guards are removed. It may also be used to alert againstunsafe practices.

CAUTION: Indicates a potentially hazardous situation that, if not avoided,may result in minor or moderate injury. It may also be used to alert againstunsafe practices.

If you have any questions not answered in this manual or require additional copiesor the manual is damaged, please contact your dealer or King Kutter, Inc. P.O.Box 1200 Winfield, AL 35594 (205) 487-3202 or www.kingkutter.com

READ AND FOLLOW THE INSTRUC-TIONS IN THIS MANUAL AND ESPE-CIALLY IN THE SAFETY SECTION. FAIL-URE TO DO SO CAN RESULT IN SERI-OUS INJURY OR DEATH.

TAKE NOTE! THIS SAFETY ALERT SYM-BOL FOUND THROUGHOUT THISMANUAL IS USED TO CALL YOUR AT-TENTION TO INSTRUCTIONS INVOLV-ING YOUR PERSONAL SAFETY ANDTHE SAFETY OF OTHERS.

SAFETY

THIS SYMBOL MEANSATTENTION!

BECOME ALERT!YOUR SAFTEY IS INVOLVED

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EQUIPMENT SAFETY GUIDELINES

Safety of the operator and by standards is one of the main concerns in designing anddeveloping a mower. However, every year accidents occur which could have beenavoided by a few seconds of thought and a more careful approach to handling equip-ment. You, the operator, can avoid many accidents by observing the following precau-tions and insist those working with you, or for you, follow them.

In order to provide a better view, certain photographs or illustrations in this manual mayshow an assembly with a safety shield removed. However, equipment should never beoperated in this condition. Keep all shields in place. If shield removal becomes neces-sary for repairs, replace the shield prior to use.

Replace any safety sign that is not readable or is missing. Location of such safetysigns is indicated in this manual.

Never use alcoholic beverages or drugs that can hinder alertness or coordination whileoperating this equipment. Consult your doctor about operating this machine whiletaking prescription medications.

Under no circumstances should children under the age of 18 be allowed to workwith this equipment. Do not allow persons to operate or assemble this unit untilthey have read this manual and have developed a thorough understanding of thesafety precautions and of how it works. Review the safety instructions with all usersannually.

This equipment is dangerous to children and persons unfamiliar with its operation. Theoperator should be a responsible, properly trained and physically able person familiarwith farm machinery and trained in this equipment’s operations. If the elderly areassisting with farm work, their physical limitations need to be recognized and accom-modated.

Use a tractor equipped with a Roll Over Protective System and seat belts. (ROPS)

Never exceed the limits of a piece of machinery. If its ability to do a job, or to do sosafely, is in question- DON’T TRY IT.

Do not modify the equipment in any way. Unauthorized modification could result inserious injury or death and may impair the function and life of the equipment.

In addition to the design and the confirmation of this implement, including safety signsand safety equipment, hazard control and accident prevention are dependent upon theawareness, concern, prudence, and proper training of personnel involved in the opera-tion, transport, maintenance, and storage of the machine. Refer also to safety mes-sages and operation instruction in each of the appropriate sections of the tractor andmower manuals. Pay close attention to the safety signs affixed to the tractor and therotary mower.

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ROTARY MOWER ASSEMBLY INSTRUCTIONS

STEP 1Place rotary mower on a flat, level surface. (See Figure A)

STEP 2Remove the wired on PTO shaft, lift pins, and spacers. Loosen and re-move the(4) bolts on the lift arm brackets, that secure the lift arm supportstraps, lift arms, and lift arm braces from the shipping positions and setaside. (See Figure B)

STEP 3Install the right lift arm and lift arm support strap using (2) two short boltsand (1) one lift pin. (See Figure C) Note: The lift arm support strap hasone hole punched larger than the other. The larger hole is to be used tofasten with the lift pin. The lift arm & support straps should be fastened tothe outside of the lift arm bracket.

STEP 4Loosen and remove the (2) nuts and washers for the A-frame tailwheelsection, leaving the bolts in place. (See Figure D)

STEP 5Install both the right and left side lift arm braces by sliding them over the(2) two A-frame tailwheel bolts that were loosened in step 4. Start thenuts on the bolts, but at this time DO NOT TIGHTEN THEM. Allow the liftarm braces to rotate forward and rest against the installed lift arm. (SeeFigure E)

STEP 6Install the long top mounting bolt by inserting it through the hole in theleft side lift arm brace, the lower of the (2) two holes in the left side liftarm, the spacer, the lower of the (2) two holes in the top of the right sidelift arm (which should not be attached to the lift arm bracket at this time),and finally through the right side lift arm brace. Install a washer andstart the nut on the bolt, but do not tighten it at this time. (See FigureF,G & H) Note: You may have to move the assembly around to start thenut & washer. If unable to get the nut and washer started a "C" clampmay be necessary to compress the assembly to be able to start the nut& washer. Install the swivel (U-Shaped piece) put mounting bolt throughupper hole in left lift arm, the spacer & swivel, (making sure the 1" blockon swivel is toward the front and rests against front side of the bottomspacer), then through top hole of right lift arm, install a washer and startthe nut on the bolt, but do not tighten it at this time.

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STEP 7Using the right side lift arm as a lever, pull to the outside of the lift armbracket and inset bolt through lift arm and lift arm bracket. (See Figure I) In-stall washer and nut. Place the lift pin in the larger of the (2) holes on the lift armbrace and loosley attach the lift arm. Finally insert bolt, nut and washer to lowersection of lift arm support strap to lift arm bracket. (See Figure J)

STEP 8Tighten all nuts and bolts.

Figure A Figure B

Figure C Figure D

Figure E Figure F

Figure G Figure H

Figure I10

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BEFORE PUTTING ROTARY MOWER INTO SERVICE

(IMPORTANT-INSTRUCTIONS PRIOR TO START UP)SHIPPED WITHOUT OIL IN GEAR BOX AND WITHOUT GREASE INGREASE FITTINGS. UNIT MUST BE SERVICED BEFORE USING.

• Fill Gearbox using Multi-Purpose Gear Oil (I.E. S.A.E. 80w/90 or S.A.E.85w/140 Multi-purpose gear oil.)

• For all Grease Fittings use TYPE/grade II tube grease.

STEP 1 Place rotary mower so that the deck is secure and level.STEP 2 Remove 1/2” Pipe Plug (Located at top of gearbox) and 1/8” Pipe

Plug (located at lower 1/3 of gearbox.STEP 3 Fill gearbox using multi-purpose gear oil through top 1/2” fill hole until

gear oil is level with lower 1/8" hole.STEP 4 Replace both the 1/2” pipe plug (located at top of gear box) and

1/8" pipe plug (located at lower 1/3 of gear box) and clean away anyexcess oil.

STEP 5 Grease (with a grade II type tube grease)The following zerks:*Tail wheel wheel fork (See Figure M-1, page 23).*Tail wheel fork (See Figure M-1, page 23).*Both U-Joints on the PTO shaft (See Figure M-2, page 23).

STEP 6 Inspect all guards to insure they are in good working order. If not re-place before using.

STEP 7 Check all bolts and nuts to insure they are tight and secure.

CAUTION:DO NOT over fill gearbox. This could cause damage to oil seals and can causepermanent damage to the gearbox. This issue will not be covered under war-ranty.

SAFETY TRAINING

Safety is a primary concern in the design and manufacture of our product.Unfortunately, our efforts to provide safe equipment can be wiped out by asingle careless act of an operator or bystander.

In addition to the design and configuration of equipment, hazard control andaccident prevention are dependent upon the awareness, concern, prudenceand proper training of personnel involved in the operation, transport, mainte-nance and storage of this equipment.

It has been said, “ The best safety device is an informed, careful operator.”We ask you to be that kind of operator. It is the operator’s responsibility toread and understand all safety and operating instructions in the manual andto follow them. Accidents can be avoided.

Working with unfamiliar equipment can lead to careless injuries. Read thismanual, and the manual for your tractor, before assembly or operating, toacquaint yourself with the machines. If this machine is used by any personother than you, or is loaned or rented, it is the rotary mower owner’s respon-sibility to make certain that owner's manual be available to the operator priorto operating:

1- Reads and understands the operator’s manuals.2- Is instructed in safe and proper use.

Know your controls and how to stop tractor, engine, and the mower quickly inan emergency. Read this manual and the one provided with your tractor.

Train all new personnel and review instructions frequently with existing work-ers. Be certain only a properly trained and physically able person will oper-ate the machinery. A person who has not read and understood all operatingand safety instructions is not qualified to operate the machine. An untrainedoperator exposes himself and bystanders to possible serious injury or death.If the elderly are assisting with farm work, their physical limitations need tobe recognized and accommodated.

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PREPARTION

Never operate the tractor and mower until you have read and completely understand thismanual, the Tractor Operator’s Manual, and each of the safety messages found on thesafety signs on the tractor and mower.Personal protection equipment including hardhat, safety glasses, safety shoes, andgloves are recommended during assembly, installation, operation, adjustment, mainte-nance, repairing, removal, or moving the implement. Do not allow long hair, loose fittingclothing, or jewelry to be around equipment.PROLONGED EXPOSURE TO LOUD NOISE MAY CAUSE PERMANENT HEARINGLOSS! Tractors with or without mowers attached can often be noisy enough to causepermanent, partial hearing loss. We recommend that you wear hearing protection on afull-time basis if the noise in the operator’s position exceeds 80 db. Noise over 80 dbon a long-term basis can cause severe hearing loss. Noise over 90 db adjacent to theoperator over a long-term basis may cause permanent, total hearing loss. NOTE: Hearingloss from loud noise (from tractors, chain saws, radios, and other such sources closeto the ear) is cumulative over a lifetime without hope of natural recovery.Operate the mower only with a tractor equipped with an approved Roll-Over-ProtectiveSystem (ROPS). Always wear your seat belt. Serious injury of even death could resultfrom falling off the tractor — particularly during a turnover when the operator could bepinned under the ROPS or the tractor.Clear area to be cut of stones, branches or other debris that might be thrown, causinginjury or damage.Operate only in daylight or good artificial light.Ensure mower is properly mounted, adjusted and in good operating condition.Ensure that all safety shielding and safety signs are properly installed and in goodcondition.

STARTING AND STOPPING SAFETY

Check the tractor master shield over the PTO stub shaft. Make sure it is in goodcondition and fastened securely to the tractor. Purchase a new shield if old shield isdamaged or missing.All tractors that are not equipped with a “live” power takeoff (PTO) need to be equippedwith an over-running PTO clutch. These are available through most farm equipmentstores. NOTE: The addition of an over-running PTO clutch may change the length ofthe PTO driveline required. Pay extra attention to the instructions on the PTO drivelineInstallation. Be sure that the driveline system guarding is adequate.Mower operating power is supplied from tractor PTO. Refer to your tractor manual forPTO engagement and disengagement instructions. Know how to stop tractor and mowerquickly in case of an emergency.When engaging PTO, the engine RPM should always be at idle speed. Once engagedand ready to start cutting, raise PTO speed to 540 RPM and maintain throughout cuttingoperation.

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OPERATIONAL SAFETY

The use of this equipment is subject to certain hazards that cannot be pro-tected against by the mechanical means or product design. All operators ofthis equipment must read and understand this entire manual, paying particu-lar attention to safety and operating instructions, prior to using. If there issomething in this manual you do not understand, ask your supervisor, oryour dealer, to explain it to you.Most accidents occur because of neglect or carelessness. Keep all help-ers and bystanders at least several hundred feet from an operating rotarymower. Only properly trained people should operate this machine.When machine is operated in populated areas where thrown objects couldinjure persons or property, operation must be stopped when anyonecomes within several hundred feet.The majority of the accidents involve entanglement on the driveline, injury ofbystanders by the objects thrown by the rotating blades, and operators be-ing knocked off the tractor by low hanging limbs and then being run over bythe mower. Accidents are most likely to occur with machines that are loanedor rented to someone who has not read the owner’s manual and is not famil-iar with a rotary mower.The rotary mower is designed for use only on tractors with 540-RPM powertake off.Install and secure all guards and shields before starting or operating. Theflaps, driveline guards and tractor shields should be used and maintained ingood working condition. They should be inspected carefully, at least daily,for missing or broken chain links, shields, or guards. (Worn items must bereplaced at once to reduce possibility of injury)Disengage power takeoff (PTO) and place transmission in neutral beforeattempting to start engine.Many varied objects, such as wire, cable, rope, or chains, can become en-tangled in the operating parts of the mower. These items could then swingoutside the housing at greater velocities than the blades. Such a situation isextremely hazardous. Inspect the cutting area for such objects before mow-ing. Remove any like objects from the site.

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OPERATIONAL SAFETY continued...

Never allow the cutting blade to contact such items. Cut material higher atfirst, allowing rotary mower to clear hidden objects. Never assume an areais clear. Always Check!Always stop the tractor, disengage PTO, set brake, shut off the tractor en-gine, remove the ignition key, lower implement to the ground and allow mowerblades to come to a complete stop before dismounting tractor. Never leaveequipment unattended with the tractor running.Never place hands or feet under mower with tractor engine running or be-fore you are sure all motion has stopped. Stay clear of all moving parts.Do not reach or place any part of your body under equipment until it is blockedsecurely.Do not allow riders on the rotary mower or tractor at anytime. There is nosafe place for any riders.Do not operate unless all personnel, livestock, and pets are several hun-dred feet away to prevent injury by thrown objects.Never operate tractor and rotary mower under trees with low hanging limbs.Operators can be knocked off the tractor and then run over by the rotatingblades.The rotating parts of this machine have been designed and tested for rug-ged use. However, they could fail upon impact with heavy, solid objectssuch as steel guardrails and concrete abutment. Such impact could causethe broken objects to be thrown outward at very high velocities. To reducethe possibility of property damage, serious injury, or even death, never allowthe cutting blades to contact such obstacles.Stop mower and tractor immediately upon striking an obstruction. Turn en-gine off, remove key, inspect and repair any damage before resuming op-eration.Stay alert for uneven terrain, holes, rocks, and roots and other hidden haz-ards. Keep away from drop-offs and hazards that could cause roll over.Use extreme care and maintain minimum ground speed when transportingor operating on hillsides, over rough ground and when operating close toditches or fences. Be careful and slow down when turning sharp cornersand changing direction on slopes. Do not start or stop suddenly on slopes.Avoid operation on steep slopes. In extremely uneven terrain, rear wheelsweights, front tractor weight, and/or tire ballast should be used to improvestability.

OPERATIONAL SAFETY continued...

Pass rotary mower diagonally through sharp dips and avoid sharp drops toprevent “hanging up” tractor and rotary mower. Practice will improve yourskills in maneuvering on rough terrain. Always cut down slopes, never acrossthe face. Always check tractor manual for proper use on slopes.When using a unit, a minimum 20% of tractor and equipment weight must beon tractor front wheels. Without this weight, the tractor could tip over, caus-ing personal injury or death. The weight may be attained with a front- endloader, front wheel weights, ballast in the tires or front tractor weights. Whenattaining a minimum 20% of tractor and equipment weight on the front wheels,you must not exceed the ROPS weight certification. Weigh the tractor andequipment. Do not guess or estimate!

TRANSPORT SAFETY

Comply with state and local laws governing highway safety and movementof farm machinery on public roads.The use of flashing amber lights is acceptable in most localities. However,some localities prohibit their use. Local laws should be checked for alllighting and marking requirements.At all times, when driving the tractor and equipment on the road or highwayunder 20mph (32kph) use flashing amber warning lights and a slow movingvehicle (SMV) identification emblem. Do not exceed 20 mph (32 kph). Re-duce speed on rough roads and surfaces.Plan your route to avoid heavy traffic.Always install transport locks, pins or brackets before transporting.Do not drink and drive.Be a safe and courteous driver. Always yield to oncoming traffic in all situa-tions, including narrow bridges, intersections, etc. Watch for traffic whenoperating near or crossing roadways.Turn curves or go up or down hills only at a low speed and at a gradualsteering angle. Make certain that a least 20% of the tractor’s weight is onthe front wheels to maintain safe steerage. Slow down on rough or unevensurface. Always check tractor manual for proper use on slopes.Use extreme care and maintain minimum ground and when operating closeto ditches or fences. Be careful when turning sharp corners.Never allow riders on either tractor or mower.

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ATTACHING TO TRACTOR

WARNINGNever stand between

tractor and rotary mowerwhile backing up tractor

to the hitch.STEP 1

Attach to tractor's category 1, three point hitch as described in theTractor's Operator’s Manual.

STEP 2Determine if the PTO shaft needs to be shortened.

NOTE:Due to the many variations in the tractor hitch points and distances be-tween equipment gearbox input shaft and tractor PTO out put shafts, somecombinations may require PTO shafts to be shortened as described bythe following steps.

STEP 3Raise and lower rotary mower in order to locate the shortest distance be-tween equipment gearbox input shaft and tractor PTO output shaft. Withthe rotary mower in the shortest distance position shut down the tractorand SECURELY BLOCK ROTARY MOWER IN POSITION.

STEP 4Pull apart PTO shaft and attach outer section to tractor PTO output shaft.NOTE: Be sure to pull on PTO shaft section to ensure yoke has lockedinto place.

STEP 5Place and hold inner PTO shaft section next to outer section and check ifPTO shaft is too long. Each section should end approximately 3 inchesshort of reaching u-joint shield on the opposite section. If the shaft is toolong measure 3 inches back from each u-joint shield and mark the othershaft section. Be sure to do this for both PTO shaft halves. NOTE: Donot cut PTO shaft sections at this time.

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ATTACHING TO TRACTOR continued....

STEP 6Raise rotary mower and remove blocking. Raise and lower rotary mowerin order to locate the longest distance between equipment input shaft andthe tractor PTO output shaft. With the rotary mower in the longest distanceposition, shut down the tractor and SECURELY BLOCK THE ROTARYMOWER IN POSITION.

STEP 7As in step 5 hold PTO shaft sections together and check for a minimum of6 inches of overlap. If PTO shaft has been marked for cutting the overlapis the distance measured between the two marks. If the PTO shaft hasless than a 6 inch overlap, DO NOT USE. Contact your authorized KingKutter Dealer.

NOTEIf the PTO shaft length is too long go to SIZING PTO SHAFT (page 19)

STEP 8Apply any multi-purpose grease to the outside of the male (inner) PTOshaft section. Assemble PTO shaft and install on rotary mower and tractor.

NOTE: If you shear the bolt that attaches the PTO shaft to the gear box replacewith a grade 2 bolt only . Replacement with another grade of bolt will voidyour warranty and may cause terminal damage to the PTO shaft, gearbox,or tractor. (King Kutter shear pin 5 pack part #500101)

WARNING

Failure to install retaining clip on gearbox input shaft would allow drivelineto swing freely if bolt is sheared causing possible injury or death.

STEP 9Pull on tractor side of PTO shaft yoke to be sure it has locked in place.Make certain PTO shaft shielding is in place and good working condition.

STEP 10The PTO shaft shield is a non-rotating design and must be secured priorto equipment use. Using the chain on each yoke shield attach to a fixedobject on the tractor and equipment ends that will not allow the PTO shaftshield to rotate during operation.

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19

STEP 1

Cutting the PTO shaft to length.NOTE: Be sure to cut equal lengthsof each PTO shaft section. Clampend of PTO shaft in a vice and cutoff shield where marked. (Figure1-A & 1-B)

STEP 2

Using cut section of the shield as aguide cut shaft off the same amount.(Figure 2)

STEP 3

Repeat steps 1 and 2 for other PTOshaft section.

STEP 4

Use a file to deburr PTO shafts.Clean up all chips, burrs and filingsfrom both ends of the PTO shaft.

SIZING PTO SHAFT

Figure 1-A

Figure 1-B

Figure 2

OPERATING INSTRUCTIONS

This mower was designed to CUT PASTURE GRASS AND ROUGH AREAS UP TO 1" INDIAMETER.. Use of your rotary mower to cut any material larger than 1" in diameter maydamage the mower and void your warranty.

PRE-OPERATIONAL ADJUSTMENTS

Set tractor's lIft control stop at a position that will prevent the PTO shaft from coming in contactwith the front edge fo the mower when it is at full lift. Consult your tractor manual for instructions.

CUTTING HEIGHT ADJUSTMENT

To prevent mower blades from striking the ground or hidden objects, your mower should beset to the highest position that will give the desired cutting height. By setting your mower upthis way you reduce blade wear and stress to the mower. Mowing at regular intervals will yeildfar better results than periodic mowings (i.e. less wind rowing). To adjust cutting heights followthese steps.

STEP 1Raise rotary mower off the ground with the tractor and SECURELY BLOCK IN POSITION.Remove 5/8" bolt from adjusting bracket. (See Figure K)

STEP 2Move the A-frame tailwheel up or down to desired cutting height. Re-install 5/8" bolt and tightento secure in position. (See Figure L)Note: It may be necessary to loosen the A-frame tailwheel attachment bolts.(See Figure D, page 9)

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Figure K Figure L

Note: For best results in heavier cutting conditions adjust the deck so the rear of themower is approximately 2" higher than the front. This method requires less horsepowerand ground speeds of approximately 3-5mph. If finer shredding results are desired,adjust the deck to level or slightly lower in the rear. This method will keep foilage under thedeck longer resulting in finer pieces. The down side of this method is if it takes alot morehorsepower and very slow ground speed. This method is not reccommended unless aPTO speed of 540 RPM can be maintained.

ROTARY MOWER OPERATION

STEP 1Before each use perform the maintenance described in maintenance section. (page 22)

STEP2Read, understand, and follow the information on safety training, preparation, starting andstopping safety, operational safety, transport safety warning sections of this manual (pages11 thru 16)

STEP 3With tractor running, lower rotary mower into working position.

STEP 4With the tractor at idle RPM, engage PTO and slowly advance throttle to 540 PTO RPM.NOTE: Rotary mower designed to run at 540 PTO RPM only.

STEP 5Select a low gear for the tractor and begin to mow. Tractor ground speed is to be con-trolled by gear selection only and not engine speed. Tractor ground speed should allowrotary mower to maintain 540 PTO RPM and thus maximum blade tip speed.

NOTE: Do not allow the tractor engine or rotary mower to bog down or stall. This causesundue wear and tear on the mower and tractor. If this continues to happen reduce groundspeed and raise cutting height of rotary mower until the 540 PTO RPM is able to bemaintained.

Never attempt to clean out a plugged discharge chute until the tractor has beenshut down and the mower blades have completely stopped.

STEP 6After each use clean all debris from the top and bottom of the rotary mower. Replace anymissing or illegible safety decals. Inspect for any damaged or worn parts and replacebefore next use. Store rotary mower in a dry environment.

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MAINTENANCE

1). Periodically check and maintain proper gear oil level.

2). Every 8 hours, wheel fork(s), wheel hub(s), PTO shaft universaljoints (2), and PTO telescoping surface. (See Figures M-1 & M-2)

NOTE: Use only a grade Type II tube grease.

3). Before each use check to make sure all safety features are in-stalled and working properly.

4). Keep blades sharp and balanced at all times. When replacingblades, replace all blades and blade bolts at the same time.

5). Periodically check all nuts and bolts to insure they are tight andsecure.

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Figure M-1(grease points at arrows)

Figure M-2(U-joints)

MAINTENANCE SAFETY

Good maintenance is your responsibility. Poor maintenance is an invitationto trouble.

Follow good shop practices.Keep service area clean and dryBe sure electrical outlets and tools are properly groundedUse adequate light for the job at hand.

Make sure there is plenty ventilation. Never operate the engine of the tractorin a closed building. The exhaust fumes may cause asphyxiation.Before working on this machine, disengage the PTO, shut off the engine,set the brakes, and remove the ignition keys.Be certain all moving parts on attachments have come to a complete stopbefore attempting to perform maintenance.Never work under equipment unless it is blocked securely.Always use personal protection devices such as eye, hand and hearing pro-tectors, when performing any service or maintenance.Frequently check mower blades. They should be balanced, sharp, free ofnicks and cracks and securely fastened.Periodically tighten all bolts, nuts, and screws and check that all cotter pinsare properly installed to ensure unit is in safe condition.When completing a maintenance or service function, make sure all safetyshields and devices are installed before placing unit in service.After servicing, be sure all tools, parts and service equipment are removedfrom mower.Do not allow debris, grease or oil to build up on any deck or platform.Where replacement parts are necessary for periodic maintenance and ser-vicing, genuine factory replacement parts must be used to restore your equip-ment to original specifications.The manufacturer will not be responsible for injuries or damages caused byuse of unapproved parts and/or accessories.A fire extinguisher and a first aid kit should be kept readily accessible whileperforming maintenance on this equipment.

STORAGE SAFETYFollowing operation, or when unhooking the mower, stop the tractor, set thebrakes, disengage the PTO, shut off the engine and remove the ignition keys.Store the unit in an area away from human activity.Do not park equipment where it can be exposed to direct contact to live-stock for long periods of time. Damage and livestock injury could result.Make sure all parked machines are on a hard, level surface and engage allsafety devices.

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24

SAFETY SIGN LOCATIONS

The types of safety signs and locations on the equipment are shown in the illustra-tion below. Good safety requires that you familiarize yourself with the varioussafety signs, the type of warning and the area, or particular function related to thatarea, that requires your SAFETY AWARENESS

REMEMBER: If safety signs have been damaged, removed, become illegible orparts have been replaced without signs, new safety signs must be applied. Newsafety signs are available from your authorized dealer, distributor or factory.

25

1

26

2

3

4

5

27

6

7

28

8

29**Must specify name brand of PTO.

Ref.

No.

Part Name

147034

1 Roll Pin Kit

2

3

4

Male Tube End Yoke

Implement End Yoke

Female Tube End Yoke

500133

151065

151060

151070

3

2

1

4

5

7

6

9

Tractor End Yoke

Inner Tube

Outter Tube

Cross Kit #4

5

6

7

8

9

151055

151092

151093

170020

170110

Safety Shield BYPY 124315

8

10

10

147029

500131

151045

151040

151050

151035

151090

151091

170015

170110

124310

147022

500131

151045

151040

151050

151035

151090

151091

170015

170110

124310

Part Number

SHEAR PIN PTO SHAFT

Safety Shield Eurocardan 12431610 124311124311

Quick Disconnect Pin

30

Ref.

No.

Part Name

1 Cross Kit

2

3

4

Roll Pin

Female Tube End Yoke

Inner Tube

Slip Clutch Assembly

Male Tube End Yoke

Outer Tube

Tractor End Yoke

Quick Disconnect Pin

5

6

7

8

9

Safety Shield BYPY10

147248147134

Part Number

147129

170015

170120

151050

151090

-

151045

151091

151035

170110

124310

170020

170120

151070

151092

-

151065

151093

151055

170110

124315

170020

170120

151070

151092

-

151065

151055

170110

124315

10

1

2

3

7

4

6

8

9

5

SLIP CLUTCH PTO SHAFT

10 124311Safety Shield Eurocardan 124316124316

151093

31

SLIP CLUTCH ASSEMBLY

Ref.

No.

Part Name

8"

Clutch Spring with Compression Bolts & Nuts (Pkg 8)1

7"

Part Number

Flanged Yoke2

Sleeve3

Clutch Plate4

Friction Hub5

Slip Clutch Lock Bolt6

Slip Clutch Liner Plate7

Pressure Plate8

500140

196006

196005

196008

196004

147350

196002

196001

500140

196011

196005

196003

196007

147350

195998

196015

1

2

3

4

5

6

7

8

1

1

32 * Depending on the size of rotary mower purchased, the blade carrier can be any of these 2 types.

Tire & Rim /w Hub

Ref.No.

Part Name

1

2

3

4

Wheel Fork Assembly

Wheel Hub Assembly

A-Frame Assembly

A-Frame Ht. Adj.

Gear Box Slick

Lift Arm Brace

PTO Shaft w/ Slip Clutch

Lift Arms

5

6

7

8

9

Part Number

10

11

12

CAT. 1 Lift Pins (Pkg. of 2)

Lift Arm Support Strap

403001

403019191100

401019

310081

184005

310074

147129

310088

500001

310071

403001

403019

401018

310081

184000

310076

-

310088

500001

310071

403001

403019191100

401022

310081

184000

310075

-

310087

500001-

13

Blade Carrier*

403031403031-Stump Jumper*

--403030

15

Blade Bolt Set (Pkg. of 2) 501001501001501001

Rotary Mower Size

ROTARY MOWER - LIFT

Mower Blade Set(Pkg. of 2) 501124501118501118

16 501027501027501027Swivel Kit

403001

403019191100

401019

310081

184060

310074

147134

310088

500001

310071

403032

-

501001

501124

501027

403001

403019191100

401020

310081

184060

310073

147134

500001

310071

403032

-

501001

501130

501027

403001

403019191100

401020

310081184005

310073

147134

310091

500001

310071

403031

-

501001

501130

501027

5-1/2'- 40hp 5-1/2'- 60hp 6'- 40hp 6'- 60hp40"- 40hp 4'- 40hp 5'- 40hp 5'- 60hp403001 403001

403019 403019191100 191100

310081 310081

184005 184060

401017 401017

310079

147134147134

310091310091

500001500001

310071310071- -

403032403031

501001 501001

501127501127

501027 501027

191100

310079

Gear Box Splined6 184010-- 184065 184065184010184010 184065

PTO Shaft w/ Shear Pin8 147029147022147022 147029 147034147034147034147034

17 501013501013501013Wheel Washer Kit 501013 501013501013501013 501013

310091

14

18 500101500101500101 500101 500101500101500101 500101Shear Bolt Kit (Pkg. 5)

33

Ref.No.

Part Name

1 Tire & Rim /w Hub

2

3

4

Wheel Fork Assembly

Wheel Hub Assembly

A-Frame Assembly

A-Frame Ht. Adj.

Gear Box

Lift Arm Brace

PTO Shaft

Lift Arm Assembly

5

6

7

8

9

Part Number

10

11

12

CAT. 2 Lift Pins (Pkg. of 2)

Swivel Yoke Assembly

501000

403602

191200

401023

310081

184080

310080

147134

5'/80hp

403656

500002

403455

501000

403602

191200

401023

310081

184065

310080

147134

5'/60hp

403656

500002

403455

13

Blade Carrier 403041403041

14

Blade Bolt Set (Pkg. of 2) 501002501002

Rotary Mower Size

HEAVY DUTY LIFT 5' MOWER

Mower Blade Set(Pkg. of 2) 501224501224

34

501000

403602

191200

403600

184080

310619

147134

403658

6'/80hp

403402

500002

195170

501000

403602

191200

403600

184065

310619

147134

403658

6'/60hp

403402

500002

195170

403041403041

501002501002

501230501230

HEAVY DUTY LIFT 6' & 7' MOWER

Ref.No.

Part Name

1 Tire & Rim /w Hub

2

3

4

Wheel Fork Assembly

Wheel Hub Assembly

Cross Axle Assembly

Lift Arm Brace

PTO Shaft

Lift Arm Assembly

Swivel Yoke Assembly

5

6

7

8

9

Part Number

10

11

12

CAT. 2 Lift Pins (Pkg. of 2)

Rachet Jack

13

Blade Carrier

14

Blade Bolt Set (Pkg. of 2)

Rotary Mower Size

Mower Blade Set(Pkg. of 2)

310609

147248

403658

403402

500002

195170

403033

501002

501230

7'/80hp

501000

403602

191200

403601

184080

310609

147248

403658

403402

500002

195170

403033

501002

501230

7'/60hp

501000

403602

191200

403601

184065Gear Box

Ref.No.

Part Name

1 Tire & Rim /w Hub

2

3

Cross Axle Assembly

Wheel Hub Assembly

Gear Box

PTO Shaft

5

6

403001

403564

191100

184060

147148

6'/60hpPart Number

403001

403564

191100

184005

147148

6'/40hp

403001

403560

191100

184060

147148

5'/60hp

403001

403560

191100

184005

147148

5'/40hp

403001

403548

191100

184005

147029

4'

4030324030329 Stump Jumper 403031403031403031

10 Blade Bolt Set (Pkg. of 2) 501001501001501001501001501001

Rotary Mower Size

ROTARY MOWER - PULL

11 Mower Blade Set(Pkg. of 2) 501130501130501124501124501118

403001

403564

191100

184080

147248

6'/80hp

403032

501001

501130

4 Top Link CAT. 1 195166195166195166195166195166 195166

Pull Tongue Assembly7 403648403648403648403648403648 403648

Axle Cuff8 320160320160320160320160320160 320160

12 500101 500101Shear Bolt Kit (Pkg. 5) 500101 500101 500101 500101

35

7' PULL MOWER

Ref.No.

Part Name

1 Tire & Rim /w Hub

2

3

4

Cross Axle Assembly

Wheel Hub Assembly

Rachet Jack

Gear Box

PTO Shaft

Pull Arm (Fits Left or Right Side)

Axle Cuff

Swivel Yoke Assembly

5

6

7

8

9

Part Number

10

11

12

Blade Carrier

Blade Bolt Set (Pkg. of 2)

Rotary Mower Size

Mower Blade Set (Pkg. of 2)

147248

403658

320160

403403

403033

501002

501230

7'/80hp

501000

403568

195170

184080

147248

403658

320160

403403

403033

501002

501230

7'/60hp

501000

403568

191100

195170

184065

36

191100

37

BONDIOLI- (BYPY)1). There are 3 white tabs around the cover as shown in (A in FIG. 1). Take a

screwdriver and press against the tabs one at a time with downward an-gular pressure toward the end of shaft marked (B in FIG. 2). As you arepressing tab grasp cover at point marked (B in FIG. 2) and apply pres-sure against cover in the direction of arrow, do this for each tab. (Some-times the other tabs may relock, if they do you must repeat unlock proce-dure.) You will feel it click when the tab releases, after all 3 tabs are re-leased you can slide the cover down the shaft in direction of (C in FIG. 2).

2) To put cover back into place slide cover back toward end until all the tabsrelock. (You may have to tap lightly with screwdriver or hammer handle).NOTE: Cover may be longer on some models but, they will come offthe same as above.

EUROCARDAN SERIES 41) First you must locate the black tab (D in FIG. 3) put flat screwdriver in slot

in end of tab and turn until the flat side is pointing towards center of shaft.Once you do this take the thin flat screwdriver and put into slot labeled (Ein FIG. 3) pry tab all the way out as shown in (FIG. 3)

2). There are 3 white tabs around the cover as shown in (G in FIG. 4). Youmust line up cover slots and tabs (as shown in FIG. 4, F & G) Take ascrewdriver and press against the tabs one at a time with downward an-gular pressure toward the end of shaft. As you are pressing tab graspcover and apply pressure against cover in the direction of arrow,(H inFIG-3) do this for each tab. (Sometimes the other tabs may relock, if theydo you must repeat unlock procedure.) You will feel it click when the tabreleases, after all 3 tabs are released you can slide the cover down theshaft in direction of (H in FIG. 3).

3) To put cover back into place slide cover back toward end (be sure tabsand slots line up) until all the tabs relock. (You may have to tap lightly withscrewdriver or hammer handle). Once they have relocked replace blacktab that was removed with flat side toward shaft center then turn flat sideup to lock in place.

LA MAGDALENA1) There are 3 black tabs around the cover (K in FIG. 5). Take a screwdriver

and press against the tabs one at a time with downward angular pressuretoward the end of shaft marked (J in FIG. 5). As you are pressing tabgrasp cover at point marked (J in FIG. 5) and apply pressure againstcover in the direction of arrow, do this for each tab.

2) To replace slide cover back toward end and line up black tabs with theholes and lock in place.

PTO SHAFTS COVER REMOVAL (Pictures are on next page)

BONDIOLI COVER REMOVAL

FIGURE- 1 FIGURE- 2 EUROCARDAN SERIES 4 COVER REMOVAL

FIGURE- 3 FIGURE- 4

LA MAGDALENA COVER REMOVAL

FIGURE- 5

38

39

EUROCARDAN SERIES 51). There are 2 black tabs around the cover as shown in (B in FIG. 1). Take a

flat screwdriver and pry under the tabs one at a time at point (B in FIG. 2)lifting tab over on top of (e-shaped lock). After both tabs are releasedyou can slide the locking ring down the shaft in direction of (C in FIG. 3).Then you will see a metal e-ring (E in FIG. 4) at point (D in FIG. 4) youmust pry under ring and remove it, (it will just slide down shaft unless youtake PTO apart) then apply pressure against cover (A in FIG. 1) in thedirection of arrow and slide cover down shaft.

2) To put cover back into place slide cover back toward end, making surecover and locking mechanism (F in FIG. 4) line up. Replace metal e-ring,slide the locking ring back into place, be sure the tabs lock securely overlocks.NOTE: Cover may be longer on some models but, they will come offthe same as above.

PTO SHAFTS COVER REMOVAL

FIGURE- 1 FIGURE- 2

FIGURE-3 FIGURE-4

40 HP GEARBOX

40

41

Ref.

No.

Part Name Gearbox

184010

1 Snap Ring

2

3

5

7

9

11

12

13

14

15

16

17

19

10

8

4

6

Input Seal (NAK35X54X10)

Front Cap

Front Cap Gasket

Snap Ring

Snap Ring

Bearing (Hoover 208)

Input Gear

Input Shaft

Bearing (NSK6207)

Housing

Output Shaft

Spacer

Output Seal (NAK40X54X7)

Bottom Cap

1" Castle Nut/w Washer & Cotter Pin

1/2" Pipe Plug

1/8" Pipe Plug

3/8" x 1" Bolt & Lockwasher

106138

156010

129015

131031

155005

186010

155010

129010

185006

131045

156005

124131

129005

501110

131035

131040

-

185010

124130

131030

184000

106138

156010

129015

131031

155005

186010

129010

185005

-

156005

124131

129005

501110

131035

131040

-

185007

124130

131030

184005

106138

156010

129015

131031

155005

186010

155010

129010

185006

131045

156005

129005

501110

131035

131040

-

185010

124130

131030

18

20

Bottom Cap Gasket

155010

124131

60 HP GEARBOX

42

43

Ref.

No.

Part Name Gearbox

184060 184065

1 Seal Input (NAK SC 35X60X10) 156040

2

3

5

7

9

11

12

13

14

15

16

17

18

19

20

129025

124133

155020

185015

129020

185035

155035

155040

186022

124134

156035

129030

501110

131035

131040

-

10

8 186020

4 155015

6 131050

Endcap Input

Gasket Input

Bearing Race Input (Timken LM603014)

Bearing Input (Timken LM603049)

Spacer 1/4"

Input Gear

Input Shaft

Housing

Gear Output

Bearing Race Output (Timken 363)

Bearing Output (Timken 368)

Output Shaft

Gasket Output

Seal Output (TCM 50X68X9TC)

Endcap Output

1" Castle Nut/w Washer & Cotter Pin

1/2" Pipe Plug

1/8" Pipe Plug

3/8" x 1" Bolt & Lockwasher

156040

129025

124133

155020

185026

129020

185035

155035

155040

186022

124134

156035

129030

501110

131035

131040

-

186015

155015

131050

1 2

3

4

5

6

7

8

9

10

11

10

7

6

12

13

14

15

14

16

17

18

19

20

80 HP GEARBOX

44

Ref.

No.

Part Name Gearbox

184080

1 1/2" Vented Pipe Plug

2

3

5

7

9

11

12

13

14

15

16

17

18

19

20

10

8

4

6

Seal Input (NAK SC 35X60X10)

1/8" Pipe Plug

Endcap Input

Gasket Input

Bearing Race Input (Timken LM603014)

Bearing Input (Timken LM603049)

Spacer

Gear Input

Snap Ring

Shaft Input

Gear Output

Bearing Race Output (Timken 362A)

Bearing Output (Timken 368)

Shaft Output

Bearing Race Output (Timken 362)

Gasket Output

Seal Output (TCM 50X68X9TC)

Endcap Output

1" Castle Nut/w Washer & Cotter Pin

131035

156040

131040

124133

155020

185015

131025

186040

185035

155037

155040

186035

155036

124134

156035

129030

501110

-

129025

155015

45

1. Limited Warranty.King Kutter, Inc. (“King Kutter”), P.O. Box 1200, Winfield, Alabama 35594, warrants to the original retail purchaser(“Purchaser”) that the product that is the subject of this sale is free from defects in material and workmanship at thetime of sale.

Under this warranty, King Kutter will repair the defective product free of charge to the Purchaser, with either new orused and reconditioned replacement parts. All warranty service will be performed at service centers designated byKing Kutter. If King Kutter is unable to repair the product to conform to the warranty after a reasonable number ofattempts, King Kutter will provide, at its option, one of the following: (a) a replacement for the product or, (b) a fullrefund of the purchase price. Repair, replacement, or refunds are the Purchaser’s EXCLUSIVE remedies againstKing Kutter under this limited warranty. King Kutter will not be liable for any special, incidental or consequentialdamages based upon breach or warranty, breach of contract, negligence, strict tort liability, or any other legal theory.Such damages include, but are not limited to, loss of profits, loss of savings or revenue, loss of use of the product orany associated equipment, cost of capital, cost of any substitute equipment, facilities or services, down time, theclaims of third parties including customers, and injury to property. These limitations also apply, to the extent allowedby law, to personal injury.

The purchaser must notify the Seller in writing of any defect in material or workmanship within one (1) year followingthe date of purchase. If the equipment is used for commercial purposes, the Purchaser must notify the Seller inwriting of any defect in material or workmanship within ninety (90) days following the date of purchase. In no event willKing Kutter be liable under this warranty unless written notice is received by the Seller within one (1) year from thedate of original retail sale.

2. Warranty of Title.King Kutter warrants that it transfers a good title to the product free of any encumbrances, and free of the rightful claimof any third party for infringement of patent or copyright.

3. What is Not Covered by This Limited Warranty.King Kutter will not be responsible for damage to or failure in the product which results from accident, misuse, abuse,neglect, installation of attachments not provided by King Kutter, modifications to the product, or damage caused byuse of the product for purposes other than those for which it was designed.

4. No Other Warranties.Unless modified in writing and signed by both parties, this agreement is understood to be the complete and exclu-sive agreement and warranty between King Kutter and Purchaser, superseding all prior agreements, oral andwritten, and all other communication between King Kutter and Purchaser related to the subject matter of this agree-ment.THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING,BUT NOT LIMITED TO, THE IMPLIED WARRANTY OF MERCHANTABILITY AND THE IMPLIED WARRANTYOF FITNESS FOR A PARTICULAR PURPOSE. No employee of King Kutter nor anyone else is authorized tomake any warranty or representation in addition to or different from those made in this agreement.

5. Allocation of Risk.This agreement allocates the risk of product failure between King Kutter and the Purchaser. This Allocation isrecognized by both parties as reflected in the price of the goods. The Purchaser acknowledges that he or she hasread this agreement, understands it, and is bound by its terms.